Exhaust material - stainless or galvanized steel?

[Michaelkov]

Talk of replacing the muffler (no matter how shabby it may be) before it is necessary is sort of getting the cart before the HORSE!

It seems I get a new muffler every Christmas, whether I need it or not...

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[KeinoDoggy]

So I pulled out of the garage and saw multiple rust spots on my concrete. The truck has 4400 miles on it and only been driven in the snow one time. I've added photos of the Maverick exhaust and bottom ones of my 2011 Outback with 274,000 miles and has gone through 11 Ohio winters. Before someone says it, yes I know it's an inexpensive vehicle. However I know for a fact that even a cheap Hyundai scooters they call cars have better quality steel in their exhausts. After all this ain't the 80's where you had to replace the exhaust every few years. Obviously this is made of mild steel, not quality steel. Maybe get another year out of this rusty mess.

 

[Darnon]

Stainless steel, particularly some form of 400-grade, will still surface rust. Just because it isn't pristine and shiny doesn't mean it isn't stainless.

 

[dalola]

Maybe Ford just spec'd corten for the exhaust, to freak everybody out.....

Will be interesting to see who/when reports the first exhaust failure. I bet it won't be as soon as some seem to think.

 

[realshelby]

Low grade stainless. Welds will rust because they are welding with mild steel wire. As long as there are no perforations, Ford is happy enough even if customers are not.
Hi temp paint can help..

 

[NoVaJimmy]

Maybe Ford just spec'd corten for the exhaust, to freak everybody out.....

Will be interesting to see who/when reports the first exhaust failure. I bet it won't be as soon as some seem to think.

Someone already reported one last year, maybe Jan or Feb, they didn't even make it through one winter. I believe they just replaced it with aftermarket instead of bothering to have Ford replace it. The muffler was visibly rusted through from the pinhole drain in the muffler.

 

[dalola]

Someone already reported one last year, maybe Jan or Feb, they didn't even make it through one winter. I believe they just replaced it with aftermarket instead of bothering to have Ford replace it. The muffler was visibly rusted through from the pinhole drain in the muffler.

Link?

 

[rclee]

If you don't drive a lot, your exhaust will rust from the inside out. Especially short trips. The condensation builds up and just sits in the muffler. The longer you drive the hotter the exhaust gets and the condensation will dry out on the longer trips.

That is one of my concerns about the Hybrid. With the engine cycling on and off, does the exhaust really get to the desired temperature to dry itself out?

 

[Michaelkov]

Link?

 

[Pow_Hound]

Wow this has been a surprisingly difficult question to pin down for certain, @KeinoDoggy pictures seem to indicate a mix of materials to me low quality stainless on the muffler and tip with galvanized pipe behind it.... Also my word where are you that you have that much rust after 1 snow storm and 4k miles???? Must be east coast?

 

[KeinoDoggy]

Wow this has been a surprisingly difficult question to pin down for certain, @KeinoDoggy pictures seem to indicate a mix of materials to me low quality stainless on the muffler and tip with galvanized pipe behind it.... Also my word where are you that you have that much rust after 1 snow storm and 4k miles???? Must be east coast?

Northeast Ohio.
UPDATE: Sent my dealer the pictures and they were shocked. Taking it in Thursday to see if I can get it replaced under warranty.
2ND UPDATE: Took the Maverick in so the Ford Rep could look at the exhaust. Later got a call back stating they will be replacing all of the rusty parts. Of course the parts are on back order but that is no big deal. Kudos to Ford for treating this right with no arguments.
They had to order all of the exhaust system all the way from the "X" on the photo back to the tailpipe. This would also include the inline heat exchanger for the traction battery.

 

[Pow_Hound]

@KeinoDoggy super good to hear Ford / dealer is making it right and getting you a replacement!

 

[MiMav]

2ND UPDATE: Took the Maverick in so the Ford Rep could look at the exhaust. Later got a call back stating they will be replacing all of the rusty parts. Of course the parts are on back order but that is no big deal. Kudos to Ford for treating this right with no arguments.
They had to order all of the exhaust system all the way from the "X" on the photo back to the tailpipe. This would also include the inline heat exchanger for the traction battery.

That's great that they are going to replace it, but I wouldn't hold my breath that the replacement will be better. Please report back and let us know. I have doubts that it's stainless based on your pictures and others I've seen. My '14 Escape and '09 Flex never rusted like that and they have experienced many salty Michigan winter roads and short trips.

 

[MiMav]

For what it's worth, I got a loaner vehicle from the Ford dealer today and the almost new Escape with 7900 miles on it has a very rusty exhaust except for the rear muffler which is somewhat visible from the back. My 2014 Escape with 80,000 miles and multiple salty winters has a better looking exhaust. So, it's not just the Maverick that Ford has reduced cost on the exhaust.

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